Raypak 106 Installation & Operating Instructions Manual

Brand: Raypak

Model: 106

Category: Above ground pool accessories

Type: Installation & Operating Instructions Manual

This manual is also suitable for

INSTALLATION & OPERATING

INSTRUCTIONS

CATALOG NO. 6100.62B Effective: 12-18-13 Replaces: 06-21-13 P/N 241519 Rev. 3

WARNING: If the information in these

instructions are not followed exactly, a fire or

explosion may result causing property

damage, personal injury or death.

FOR YOUR SAFETY: Do not store or use

gasoline or other flammable vapors and

liquids or other combustible materials in the

vicinity of this or any other appliance. To do

so may result in an explosion or fire.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not

use any phone in your building.

• Immediately call your gas supplier from a

neighbor's phone. Follow the gas suppli-

er's instructions.

• If you cannot reach your gas supplier, call

the fire department.

Installation and service must be performed by

a qualified installer, service agency or the gas

supplier

This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for

future reference.

Models 106 & 156

Atmospheric

Above-Ground

Pool & Spa

Heater

(Chauffe-Piscine)

English/French

AVERTISSEMENT: Assurez-vous de bien suivre

les instructions données dans cette notice pour

réduire au minimum le risque d’incendie ou

d’explosion ou pour éviter tout dommage matériel,

toute blessure ou la mort.

Ne pas entreposer ni utiliser d’essence ou ni

d’autres vapeurs ou liquides inflammables à

proximité de cet appareil ou de tout autre appareil.

CE FAIRE SI VOUS SENTEZ UNE ODEUR

DE GAZ:

• Ne pas tenter d’allumer d’appareil.

• Ne touchez á aucun interrupteur; ne pas

vous servir des téléphones se trouvant dans

la bâtiment.

• Appelez immédiatement votre fournisseur

de gaz depuis un voisin. Suivre les instruc-

tions du fournisseur.

• Si vous ne pouvez rejoindere le fournisseur,

appelez le service es incendies.

L’installation et l’entretien doivent être assurés

par un installeur qualifié ou par le fournisseur de

gaz.

Rev. 2 reflects the following:

Changes to: Fig. 3 on page 10, Table F on page 13, Fig. 28 on page 29

Additions: None

Deletions: None

WARNINGS 4

Pay Attention to These Terms 4

WATER CHEMISTRY 5

Automatic Chlorinators &

Chemical Feeders 5

SAFETY 6

Water Temperature Safety 6

INTRODUCTION 6

Ratings & Certifications 6

Model Identification 7

Specifications 7

Unpacking 7

INSTALLATION 8

Installation Codes 9

Clearances 9

Base Installation 9

Outdoor Installation 9

Indoor Installation 11

Combustion & Ventilation Air 11

Gas Connections 12

Water Connections 14

Electrical Connections 16

OWNER’S OPERATING

INSTRUCTIONS 17

Control Adjustments—Analog 17

Control Adjustments—Digital 17

Thermostat Operation—Advanced Flame

Technology (AFT) Board 19

Status and Diagnostics 21

Remote Control Installation 22

Wiring Diagrams 24

Post Start-Up Inspection 25

Cold Weather Operation 25

MAINTENANCE 26

SERVICE 26

Water Pressure Switch 26

Flame Roll-Out Safety Switch 27

High Limits 27

Burner Tray Removal 28

Gas Valve Removal 28

Pilot Removal & Cleaning 29

Heat Exchanger Removal 30

Tube Cleaning Procedure 30

De-sooting Procedure 30

Replacement Parts 31

TROUBLESHOOTING 32

Mechanical 32

Electronic Control Logic Flowchart 33

Analog Control Logic Flowchart 34

ILLUSTRATED PARTS LIST 35

CONTENTS

DANGER:

Indicates the presence of immediate hazards which will cause severe

personal injury, death or substantial property damage if ignored.

WARNING:

Indicates the presence of hazards or unsafe practices which could cause

severe personal injury, death or substantial property damage if ignored.

CAUTION:

Indicates the presence of hazards or unsafe practices which could cause

minor personal injury or product or property damage if ignored.

NOTE:

Indicates special instructions on installation, operation, or maintenance which

are important but not related to personal injury hazards.

DANGER: Failure to install the drafthood on indoor

installation and properly vent the heater to the

outdoors as outlined in the venting section of this

manual can result in unsafe operation of the heater.

To avoid the risk of fire, explosion, or asphyxiation

from carbon monoxide, never operate this heater

unless it is properly vented and has an adequate air

supply for proper operation. Be sure to inspect the

vent system for proper installation at initial start-up,

and at least annually thereafter. Refer to the venting

section of this manual for more information regarding

vent system inspections.

WARNING: Gasoline, as well as other flammable

materials and liquids (adhesives, solvents, etc.), and

the vapors they produce, are extremely dangerous.

Do not handle, use, or store gasoline or other

flammable or combustible materials in the vicinity of

a heater.

WARNING: Improper installation, adjustment,

alteration, service, or maintenance can cause

property damage, personal injury or loss of life.

Refer to the owner’s operating instructions provided

in this manual. Installation and service must be

performed by a qualified installer, service agency, or

the gas supplier.

WARNING: To minimize the possibility of improper

operation, serious personal injury, fire, or damage to

the heater:

• Always keep the area around the heater free of

combustible materials, gasoline, and other

flammable liquids and vapors.

• Heater should never be covered or have any

blockage to the flow of fresh air to the heater.

WARNING - CALIFORNIA PROPOSITION

65: This product contains chemicals known to the

State of California to cause cancer, birth defects or

other reproductive harm.

WARNINGS - Pay Attention to These Terms

WARNING: Both natural gas and propane have an

odorant added to aid in detecting a gas leak. Some

people may not physically be able to smell or

recognize this odorant. If you are unsure or

unfamiliar with the smell of natural gas or propane,

ask your local gas supplier. Other conditions, such

as "odorant fade," which causes the odorant to

diminish in intensity, can also hide, camouflage, or

otherwise make detecting a gas leak by smell more

difficult.

WARNING: Do not install within 3 feet (0.9 m) of a

heat pump or an outdoor condensing unit. Strong air

intake from this type of equipment can disturb the

combustion process and cause damage or personal

injury.

WARNING: UL recognized fuel gas detectors are

recommended in all enclosed propane and natural

gas applications wherein there is a potential for an

explosive mixture of fuel gas to accumulate and their

installation should be in accordance with the

detector manufacturer's recommendations and/or

local laws, rules, regulations, or customs.

WARNING: The heater shall not be located in an

area where water sprinklers, or other devices, may

cause water to spray through the cabinet louvers and

into the heater. This could cause internal rusting or

damage electrical components, and void the warran-

ty.

WATER CHEMISTRY

Chemical imbalance can cause severe damage to

your heater and associated equipment. Maintain your

water chemistry according to Table A. If the mineral

content and dissolved solids in the water become too

high, scale forms inside the heat exchanger tubes,

reducing heater efficiency and damaging the heater. If

the pH drops below 7.2, this will cause corrosion of the

heat exchanger and severely damage the heater. Heat

exchanger damage resulting from chemical imbal-

ance is not covered by the warranty.

For your health and the protection of your pool equip-

ment, it is essential that your water be chemically

balanced. The following levels must be used as a

guide for balanced water.

• Occasional chemical shock dosing of the pool or

spa water should not damage the heater providing

the water is balanced.

• Automatic chemical dosing devices and salt chlo-

rinators are usually more efficient in heated water,

unless controlled, they can lead to excessive chlo-

rine level which can damage your heater.

• Further advice should be obtained from your pool

or spa builder, accredited pool shop, or chemical

supplier for the correct levels for your water.

Automatic Chlorinators &

Chemical Feeders

All chemicals must be introduced and completely dilut-

ed into the pool or spa water before being circulated

through the heater. Do not place sanitizing chemi-

cals in the skimmer. High chemical concentrations

will result when the pump is not running (e.g.

overnight).

Chlorinators must feed downstream of the heater and

have an anti-siphoning device to prevent chemical

back-up into the heater when the pump is shut off. See

Fig. 1.

NOTE: Corrosive water voids all warranties.

CAUTION: Free chlorine must not exceed 5 ppm

which can damage the heater and is not covered

under warranty.

NOTE: High chemical concentrates from feeders

and chlorinators that are out of adjustment will

cause rapid corrosion to the heat exchanger.

Such damage is not covered under the warranty.

Recommended Level(s) Fiberglass Pools Fiberglass Spas

Other Pool and Spa

Types

Water Temperature 68-88°F (20-31°C) 89-104°F (31-40°C) 68-104°F (20-40°C)

pH 7.3-7.4 7.3-7.4 7.6-7.8

Total Alkalinity (ppm) 120-150 120-150 80-120

Calcium Hardness (ppm) 200-300 150-200 200-400

Salt (ppm) 4500 Maximum 4500 Maximum 4500 Maximum

Free Chlorine (ppm)* 2-3 2-3 2-3

Total Dissolved Solids

(ppm)

3000 Maximum** 3000 Maximum** 3000 Maximum**

*Free Chlorine MUST NOT EXCEED 5 ppm!

** In salt water chlorinated pools, the total TDS can be as high as 6000 ppm.

Table A: Water Chemistry

Spa

Return to Spa

Fig. 1: Spa/Chlorinator Setup

SAFETY

This appliance is to be installed and operated by

trained personnel in accordance with this Installation

and Operation Manual. Be sure to read and under-

stand the entire Installation and Operation Manual

before attempting to install or operate this appliance.

Failure to follow the warnings listed at the beginning of

this manual could result in a fire or explosion, causing

property damage, bodily injury, or death.

Should you have any problems understanding the

warnings and instructions in this manual, STOP, and

get help from a qualified installer, service technician,

or the gas supplier.

Water Temperature Safety

Elevated water temperature can be hazardous. The

U.S. Consumer Product Safety Commission has these

guidelines:

1. Spa water temperatures should never exceed

104°F (40°C). A temperature of 100°F (38°C) is

considered safe for a healthy adult. Special cau-

tion is suggested for young children.

2. Drinking of alcoholic beverages before or during

spa or hot tub use may cause drowsiness which

could lead to unconsciousness and subsequently

result in drowning.

3. Pregnant Women Beware! Soaking in water over

102°F (39°C) may cause fetal damage during the

first three months of pregnancy resulting in the

birth of a brain-damaged or deformed child.

Pregnant women should stick to the 100°F (38°C)

maximum rule.

4. Before entering the spa or hot tub, users should

check the water temperature with an accurate

thermometer; spa or hot tub thermostats may err

in regulating water temperatures by as much as

4°F (2.2°C).

5. Persons with a medical history of heart disease,

circulatory problems, diabetes, or blood pressure

problems should obtain a physician's advice

before using spas or hot tubs.

6. Persons taking medications which induce drowsi-

ness, such as tranquilizers, antihistamines,

anticoagulants, or recreational drugs should not

use spas or hot tubs.

INTRODUCTION

Ratings & Certifications

This pool & spa heater (chauffe-piscine) is design-cer-

tified and tested under the latest requirements of ANSI

Z21.56 / CSA 4.7 Standard for Gas-Fired Pool Heaters

(Chauffe-Piscines). The heater can be used either

indoors or outdoors. (Installer å l’intérieur ou à l’ex-

térieur.) If necessary, the top of the heater can be

changed after installation to accommodate indoors or

outdoors.

AVERTISSEMENT: La U.S. Consumer Product

Safety Commission indique que des températures

de l’eau élevées deuvent être dangereuses. Voir la

notice d’installation et de fonctionnement pour le

réglage de lat température. Suivre les instructions

pour une installation appropriée.

WARNING: Use of any parts not manufactured

and/or approved by the manufacturer may cause

non-warrantable damage.

Ambient Temperature Rating of

Components

• Analog heater -40°F to +175°F (-40°C to 79.4°C)

• Electronic heater -32°F to +175°F (-35.5°C to

79.4°C)

Model Identification

The model identification number and heater serial

number are found on the heater rating plate.

The model identification number will be similar to the

example shown below:

Fig. 2: Location of Heater Rating Plate

Specifications

Unpacking

On receipt of the heater it is suggested that visual

checks are made for external damage to the shipping

carton. If the carton is damaged, make a note to that

effect on the Bill of Lading when signing for the ship-

ment. Remove the heater from the shipping

packaging. Report any damage to the carrier immedi-

ately.

On occasion, items are shipped loose. Be sure that the

correct number of packages are received, as indicated

on the Bill of Lading.

Claims for shortages and damages must be filed with

the carrier by consignee. Authorization to return goods

must be received from the factory prior to shipping.

Goods returned to the factory without an authorized

Returned Goods Receipt number will not be accepted.

All returned goods are subject to a restocking charge.

When ordering parts, specify the model and serial

number of the heater. When ordering under warranty

conditions, specify the date of installation. Records of

the installation must be provided, when requested, to

substantiate a claim.

Debits for defective replacement parts will not be

accepted and will only be replaced in kind per the

manufacturer's standard warranties.

Model

No.

Input*

Gas

Conn.

(NPT)

Water

Conn.

(NPT)

Shipping Weight

Std.

Heater w/

Stackless

Top

Drafthood

Assembly

106

105,000

BTU/hr.

(30.75

KW)

1/2 in.

(1.27

cm)

1-1/2 in.

or 2 in.

(3.8cm

or 5

cm)

85 lbs.

(38.6 kg)

14 lbs.

(6.35 kg)

156

150,000

BTU/hr.

(43.93

KW)

100 lbs.

(45.4 kg)

Table B: Specifications

P - R 106 A - E N - C

Plastic Header

R = Raypak

M = Rheem

D = Ruud

Model No.

Model Rev.

E = Electronic

A = Analog

N = Natural

P = Propane

C = Copper

CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California

to cause cancer, birth defects or other reproductive harm.

IMPORTANT NOTICE

These instructions are intended only for the use by qualified personnel, specifically trained and experi-

enced in the installation of this type of heating equipment and related system components. Installation

and service personnel may be required by some states to be licensed. If your state is such, be sure your con-

tractor bears the appropriate license. Persons not qualified shall not attempt to fix this equipment nor attempt

repairs according to these instructions.

WARNING: Improper installation, adjustment, alteration, service or maintenance may damage the equip-

ment, create a hazard resulting in asphyxiation, explosion or fire, and will void the warranty.

WARNING: This unit contains refractory ceramic fiber (RCF) insulation in the combustion chamber. RCF, as

manufactured, does not contain respirable crystalline silica. However, following sustained exposure to very

high temperatures (>2192F), the RCF can transform into crystalline silica (cristabolite). The International

Agency for Research on Cancer (IARC) has classified the inhalation of crystalline silica (cristabolite) as car-

cinogenic to humans.

When removing the burners or heat exchangers, take precautions to avoid creating airborne dust and avoid

inhaling airborne fibers. When cleaning spills, use wet sweeping or High Efficiency Particulate Air (HEPA)

filtered vacuum to minimize airborne dust. Use feasible engineering controls such as local exhaust ventilation

or dust collecting systems to minimize airborne dust. Wear appropriate personal protective equipment

including gloves, safety glasses with side shields, and appropriate NIOSH certified respiratory protection, to

avoid inhalation of airborne dust and airborne fiber particles.

INSTALLATION

Installation Codes

Installations must be in accordance with local, state,

provincial, and national codes, laws, regulations and

ordinances. In the absence of local codes, installations

must be in accordance with the latest editions of the:

• National Fuel Gas Code, ANSI Z223.1/NFPA 54

• National Electrical Code, ANSI/NFPA 70

• For Canada only: CAN/CSA-B149 Installation Code

(B149) and CSA C22.1 C.E.C. Part 1 and Part 2

Clearances

The required minimum clearances from combustible

surfaces are shown in Table C below.

Dégagements minimaux à assurer entre les parois de

l”appareil et les contructions combustibles: 6po

(côtés), 12po (arrière) et 30po (dessus).

When installed according to the listed minimum clear-

ances from combustible construction, the pool heater

can be serviced without removing permanent con-

struction around the heater.

Heater Side

Outdoor

Installations

Indoor

Installations

Top* Unobstructed 30 in. (76.2 cm)

Front 24 in. (61 cm) Alcove

Vent N/A 6 in. (15.2 cm)

Back 12 in. (30.5 cm) 12 in. (30.5 cm)

Right Side 6 in. (15.2 cm) 6 in. (15.2 cm)

Left Side 6 in. (15.2 cm) 6 in. (15.2 cm)

*Clearance from top of vent terminal.

Table C: Required Minimum Clearances from

Combustible Surfaces.

However for ease of servicing, we recommend a

clearance of at least 18" (45.7cm) on the rear. This

will enable the heater to be serviced in its installed

location, that is, without movement or removal of the

heater.

Minimum clearance from drafthood to combustible

construction 6 inches from the vent.

Degagement minimal de 6 po requis entre le coupe-

tirage et une construction combustible. 2 po du conduit

de raccordement.

Clearances less than recommended may require

removal of the heater to service either the heat

exchanger or the burner tray. In either case, the heater

must be installed in a manner that will enable the

heater to be serviced without removing any structure

around the heater.

Base Installation

Heater must be mounted on a level base, such as

cementable slab or cement blocks. Heaters may not

be installed on carpeting.

This heater must b e installed at least 5ft (1.52m) from

the inside wall of a pool unless separated from the

pool by a solid fence, wall or other permanent solid

barrier.

Ce chauffe-piscine doit êntre installè à au moins 5

peds (1.52m) de la paroi interne de la piscine à moins

d’êntre isolé de la piscine par un clôture, un mur ou

autre barrière permanente.

Outdoor Installation

NOTE: The heater should not be located in an area

where possible water leakage will result in damage

to the area adjacent to the heater or to the structure.

When such locations cannot be avoided, it is

recommended that a suitable drain pan, with

adequate drainage, be installed under the heater.

The pan must not restrict combustion air flow.

AVERTISSEMENT: Cet appareil doit être installé

conformément au National Fuel gas Code ANSI

Z223.1, et aux exigences de l’autorité competente.

FLOORING: This heater can be installed on com-

bustible flooring.

WARNING: The heater should not be located in an

area where water sprinklers or other devices may

cause water to spray through the cabinet louvers

and into the heater. This could cause internal rusting

or damage electrical components, and will not be

covered under warranty.

WARNING: Do not install within 3 feet (0.9m) of a

heat pump or an outdoor condensing unit. Strong air

intake from this type of equipment can disturb the

combustion process and cause damage or personal

injury.

Fig. 3: Overall Dimensions

Heater with Outdoor Stackless Top

Heaters must not be installed under an overhang of

less than 3 ft (0.9m) from the top of the heater. Three

sides must be open in the area under the overhang.

Roof water drainage must be diverted away from

heaters installed under overhangs with the use of gut-

ters.

Ne pas installer ce chauffe-piscine sous une saillie

mesurant moins de 3 pi de hauteur. La partie sous Ia

saillie doit etre ouverte sur 3 côtes.

• For U.S. installations, the point from where the flue

products exit the heater must be a minimum of 4 ft

(1.2m) below, 4 ft (1.2m) horizontally from, or 1 ft

(0.3m) above any door, window or gravity inlet into

any building. The top surface of the heater shall be at

least 3 ft (0.9m) above any forced air inlet, or intake

ducts located within 10 ft (3m) horizontally. See

Fig. 5.

• For installations in Canada, pool heaters shall not be

installed with the top of the vent assembly within 10 ft

(3m) below, or to either side, of any opening into the

building. Refer to the latest revisions of CAN/CSA-

B149. The heater must be raised 7 in (0.2m) above

the surface which could support snow, ice or debris.

Refer to the latest revisions of CAN1-2.21-M85.

Outdoor Stack

High Wind Conditions

(Outdoor Units Only)

In areas where high winds are frequent, it may be nec-

essary to locate the heater a minimum of 3 ft (0.9m)

from high vertical walls, or install a wind-break so the

heater is not in direct wind current.

In areas of daily high winds, it may be necessary to

replace the outdoor stackless top with a stack adapter

in combination with a wind-resistant/weather-proof

outdoor stack. See Fig. 4.

NOTE: The outdoor stack is optional equipment and

does not come standard with the heater. Use part

number 014718 for the 106 and 014719 for the 156.

NOTE: This heater is design-certified for outdoor

installation when equipped with the approved top(s)

for outdoor use.

OUTDOOR

STACK

Fig. 4: Outdoor Stack

Amp Draw

120 Volt 240 Volt

4 2

The outdoor stack serves the same function as the low

profile stackless top and should be installed in accor-

dance with the same clearance requirements. Follow

the installation instructions provided with the Outdoor

Stack Kit for installation.

Indoor Installation

The heater is design-certified for indoor installation

when equipped with the approved drafthood.

Locate heater as close as is practical to a chimney or

gas vent. Heater must always be vented to the out-

side. See Vent Piping section for details. Minimum

allowable space is shown on the rating plate. Follow

the installation instructions provided with the Indoor

Drafthood Kit for installation.

This drafthood must be installed without alteration. see

rating plate.

Ce coupe-tirage doit être installé sans modification.

Voir Ia plaque signalétique.

Combustion & Ventilation Air

(Indoor Units Only)

The heater must have both combustion and ventilation

air. Minimum requirements for net free air supply

openings are one opening that is 12 inches (30.5 cm)

from the ceiling for ventilation, and one opening that is

12 inches (30.5 cm) from the floor for combustion air

as outlined in the latest edition of the National Fuel

Gas Code, ANSI Z223.1 (Canada-CAN/CSA-B149)

and any local codes that may have jurisdiction.

NOTE: For Canada, indoor installation is restricted

to an enclosure that is not occupied and does not

directly communicate with an occupied area. Refer

to the latest edition of CAN/CSA-B149 for specific

requirements.

All Air from inside the building each opening shall•

have a minimum net free area as noted in Table E.

All air from outdoors when air is supplied directly•

from outside the building each opening shall have

a minimum net free area as noted in Table D.

Vent Piping

Vent piping the same size as the drafthood outlet is

recommended, however, when the total vent height is

at least 10 ft (3m) (drafthood relief opening to vent ter-

minal), the vent pipe size may be reduced as specified

in the National Fuel Gas Code, ANSI Z223.1 (Canada

- CAN/CSA-B149). As much as possible, avoid long

horizontal runs of vent pipe and too many elbows.

If installation requires horizontal runs, the vent pipe

must have a minimum of 1/4 in. (2cm per m) per ft rise

and should be supported at not more than five foot

intervals. Plumbers tape, criss-crossed, will serve to

space both horizontal and vertical piping. Gas vents

supported only by the flashing and extending above

the roof more than 5 ft (1.5m) should be securely

guyed or braced to withstand snow and wind loads.

We recommend use of insulated vent pipe spacers

through the roof and walls.

For protection against rain or blockage by snow, the

vent pipe must terminate with a vent cap which com-

plies with local codes or, in the absence of such codes,

the latest edition of the National Fuel Gas Code, ANSI

Z223.1 (Canada - CAN/CSA-B149).

WARNING: Indoor heaters require a drafthood

that must be connected to a vent ppe and properly

vented to the outside. Failure to follow this

procedure can cause fire or fatal carbon monoxide

poisoning.

Model Area

106 105 in² (677 cm²)

156 150 in² (968 cm²)

Model

Unrestricted

opening

Typical screened

or louvered opening

Typical screened

and louvered opening

106 27 in² (174 cm²) 41 in² (265 cm²) 54 in² (348 cm²)

156 38 in² (245 cm²) 57 in² (368 cm²) 76 in² (490 cm²)

CAUTION: Combustion air must not be

contaminated by corrosive chemical fumes which

can damage the heater and void the warranty. Do

not store chlorine, bromine, baquasil or acid in the

same room as the heater.

Table D: Minimum Air Net Area

Table E: Minimum Air Area

4 ft (1.2m)

1 ft (0.3m)

10 ft (3m)

4 ft (1.2m)

3 ft (0.9m)

Fig. 5: Outdoor Installation Clearances

2’ (0.6m)

MIN

10’ (3m)

OR LESS

2’ (0.6m)

MIN

5’ (1.5m)

MIN

Fig. 6: Vent Piping Requirements

The weight of the vent stack or chimney must not rest

on heater drafthood. Support must be provided in

compliance with applicable codes. The heater top and

drafthood must be readily removable for maintenance

and inspection. Vent pipe should be adequately sup-

ported to maintain proper clearances from combustible

construction.

Type "B" double-wall or equivalent vent pipe is recom-

mended. However single-wall metal vent pipe may be

used as specified in the latest edition of the National

Flue Gas Code ANSI Z223.1 (Canada - CAN/CSA-

B149).

Gas Connections

Gas piping must have a sediment trap ahead of the

heater gas controls, and a manual shut-off valve locat-

ed outside the heater jacket. All gas piping should be

tested after installation in accordance with local codes.

CAUTION: Do not use 5, 10 or 20 gallon (19.38 or

76 Liter) propane tanks, like those used with con-

sumer barbecues, to supply gas to this heater.

CAUTION: The heater and its manual shut-off

valve must be disconnected from the gas supply

during any pressure testing of that system at test

pressures in excess of 1/2 psig (3.5 kPa). The heater

and its gas connections shall be leak tested before

placing the appliance in operation. Use soapy water

for leak test. do not use open flame.

The discharge opening must be a minimum of 2 ft

(0.6m) vertically from the roof surface and at least 2 ft

(0.6m) higher than any part of the building within 10 ft.

(3m) vent stack shall be at least 5 ft (1.5m) in vertical

height above the drafthood outlet. The vent cap loca-

tion shall have a minimum clearance of 4 ft (1.2m)

horizontally from, and in no case below, unless a 4 ft

(1.2m) horizontal distance is maintained, from electric

meters, gas meters, regulators and relief equipment.

Fig. 7: Gas Line Sediment Trap

NOTE: Do not use Teflon tape on gas line pipe

thread. A flexible pipe sealant suitable for LP gases

is recommended.

Gas Pressure Regulator

The gas pressure regulator is preset at 4.0 in W.C.

(1.0kPa) for natural gas and 10.0 in W.C. (2.5kPa) for

propane gas.

If adjustment is needed, remove plug and turn adjust-

ment screw clockwise to increase pressure or

counter-clockwise to decrease pressure.

Gas Pressure* Natural Gas Propane Gas

Max. Inlet

(static)

10.5 in. WC

(2.6 kPa)

13 in. WC

(3.2 kPa)

Min. Inlet

(dynamic)

5 in. WC

(1.2 kPa)

11 in. WC

(2.7 kPa)

Manifold Gas

(dynamic)

4 in. WC

(1.0 kPa)

10 in. WC

(2.5 kPa)

*Static means without heater operating, dynamic refers to heater

operating.

Table F: Gas Pressure

Gas Pressure Adjustment Locations

Fig. 8: Honeywell Gas Valve

Electronic Ignition Gas Valves

Fig. 9: Location of Gas Pressure Adjustment

Pipe Sizing for Gas Connections

Water Connections

The heater requires water flow and positive pressure

to fire and operate properly. It must therefore be

installed downstream of the discharge side of the filter

pump. A typical installation is plumbed as follows:

1. The inlet side of the filter is plumbed directly to the

discharge side of the filter pump;

2. The outlet side of the filter is then plumbed to the

inlet of the heater; and

3. The outlet of the heater is plumbed to the return

line to the pool or spa. The pump, filter and heater

are thus plumbed in series.

Plumbing from the heater back to the pool or spa must

not have any valves or restriction that could prevent

flow when the pump is operating.

Heater must be located so that any water leaks will not

damage the structure of adjacent area. PVC pipe may

be glued directly into supplied CPVC header unions.

Flow Rates

Table G: Maximum Equivalent Pipe Length

Polymer Headers

Before attaching the supplied 2-inch (5 cm) CPVC

unions to the In/Out header, make sure the O-rings are

properly seated in the grooves. Use AquaLube or

equivalent non-petroleum-based lubricant on the O-

ring. Hand tighten the unions. Glue PVC or CPVC

piping directly to the unions.

Model No. Minimum Maximum

106/156 20 GPM (75 L) 70 GPM (265 L)

*When flow rates exceed maximum 70 GPM, an external auxiliary

bypass valve is required. See External Auxiliary Bypass Valve sec-

tion for details.

Table H: Water Flow Rates

In/Out Header

O-Ring

Tail Piece

Nut

2” Pipe

(5cm)

Drain Plug

In/Out Header

Hose Connector

Hose

Fig. 10: In/Out Header for 2" Installation

Fig. 11: Optional In/Out Header for 1-1/2" (3.8 cm)

or 1-1/4" (3.2 cm) Hose Connection

NAT LPG NAT LPG NAT LPG

105,000 BTU/hr 26 ft 65 ft 99 ft 252 ft 350 ft 892 ft

(30.8 kW) (8 m) (20 m) (30 m) (77 m) (107 m) (272 m)

150,000 BTU/hr 13 ft 34 ft 51 ft 130 ft 180 ft 459 ft

(43.9 kW) (4 m) (10 m) (16 m) (40 m) (55 m) (140 m)

* Natural Gas 1000 BTU/FT

0.60 Specific Gravity @ 0.5 in WC Pressure Drop

(Gaz Naturel 3154.5 W/m

0.60 Densité @ 0.124 kPa Pressure Drop)

* Propane Gas 2500 BTU/FT

1.53 Specific Gravity @ 0.5 in WC Pressure Drop

(Le Gaz Propane 7886.3 W/m

1.53 Densité @ 0.124 kPa Pressure Drop)

1/2 in. (1.27cm)

3/4 in. (1.91cm)

1 in. (2.54cm)

Model

Tubing

Input

106

156

If there is any possibility of back-siphoning when the

pump stops, it is recommended that a check valve (or

valves) also be installed in the system.

Internal Automatic Bypass Valve

A built-in automatic bypass valve is provided in the

In/Out header. The internal bypass valve automatical-

ly responds to changes in water pressure in the piping

system. The proper amount of water flow is maintained

through the heater under varying pressures dictated

by the conditions of the pump and filter.

External Auxiliary Bypass Valve

An auxiliary bypass valve must be used when flow

rates exceed 70 GPM (265 LPM). Usually a high-per-

formance pump size larger than one horsepower will

exceed this flow rate. This valve is required to comple-

ment the function of the automatic bypass valve,

particularly when starting the heater in winter or early

spring when the spa or pool temperature is below 50°F

(10°C). It also serves to eliminate needless pressure

drop through the heater and accompanying reduction

in the flow rate to the spa jets, etc.

Bypass Disc

Spring

Bypass Body

Fig. 12: Internal Automatic Bypass Valve

From Heater

To Heater

To Pool/Spa

Bypass Valve

From

Pool/Spa

Full Port

Ball Valve

or Globe

Valve

Fig. 13: Auxiliary Bypass Valve

NOTE: Do not use a gate valve as an auxiliary

bypass valve.

Auxiliary Bypass Valve Adjustment

To set bypass: With clean filter, adjustment is made by

feeling the inlet and outlet pipes at the heater. Outlet

pipes should be slightly warmer than inlet and comfort-

able to the touch. If pipe is hot, close bypass; if cold,

open bypass.

Pressure Relief Valve Installation

To conform to local building codes, it may be neces-

sary to install a pressure relief valve. A 3/4" (1.9 cm)

pressure relief valve, having a capacity equal to or

greater than the BTUH input of the heater to be

installed, is recommended for this heater. The maxi-

mum pressure relief valve setting is 125 psi (862 kPa).

This relief valve needs to be installed on the outlet pipe

from the header as noted in Fig. 14 below.

If required, this needs to be installed in a field-supplied

fitting external to the heater. The valve shall be

installed in a vertical position. Do not over-tighten.

Install the pressure relief valve hand tight plus 1/2 turn.

The valve lever should be tripped at least once a year

to ensure that waterways are clear. If the relief valve

does not function properly, replace it immediately.

PIPE ONTO DISCHARGE SIDE OF PIPING

Fig. 14: Pressure Relief Valve Installed

WARNING: To avoid water damage or scalding due

to relief valve operation, drain pipe must be

connected to valve outlet and run to a safe place of

discharge. Drain pipe must be the same size as the

valve discharge connection throughout its entire

length and must pitch downward from the valve. No

shut-off valve shall be installed between the relief

valve and the drain line.

Installation Instructions—240 Volt

1. Disconnect and remove 120 volt power cord.

2. Install wire nut on white transformer wire.

3. Wire nut 240 volt supply lines to the red and black

wire on the transformer.

4. Wire nut green supply ground line to green trans-

former wire

CAUTION: This heater has provisions to be

connected to an alternate supply source. To reduce

the risk of electric shock, disconnect all connections

before servicing.

240V HOOK-UP

HEATER

RED RED

BLACK

HOT

BLACK

GREENGREEN

WHITE

SUPPLY

SIDE

Fig. 16: 240V Hook-Up

Heat Exchanger Pressure Drop

Table

Electrical Connections

Be sure that electrical service to the heater has prop-

er overload fuse or circuit breaker protection, wire size

and connections which comply with all applicable

codes.

If any of the original wire as supplied with the appli-

ance must be replaced, it must be replaced with type

302°F (150°C) wire or its equivalent.

Si un des fils original fourni avec l'appareil doit être

remplacé, utilisez un fil 302°F (150°C), ou l'équivalent.

The heater comes standard with a 120 VAC 3-prong

power cord. For 240 VAC applications, see figure 18.

Power source must be a wired ground, with ground

fault circuit interruption circuitry.

Flow (GPM) Pressure Drop (ft of Head)

20 7.6

30 8.2

40 8.7

50 9.3

60 9.8

70 10.4

Table I: Pressure Drop

The heater must be electrically grounded and bonded

in accordance with local codes, or, in the absence of

local codes, with the latest edition of the National

Electrical Code, ANSI/NFPA 70. (Canada - Canadian

Electrical Code, CSA C22.1, Part 1 and Part 2.)

Fig. 15: Electronic Heater Power

NOTE: Input power to the heater (120 VAC) can be

supplied from the load (pump) side of time clock or

directly from the GFCI power source. It is preferred

to make connection to the load/pump side of the time

clock.

WARNING: Risk of electrical shock. More than

one disconnect switch may be required to de-

energize the equipment before servicing.

CAUTION: Label all wires prior to disconnection

when servicing controls. wiring errors can cause

improper and dangerous operation.

ATTENTION. Au moment de l'entretien des

commandes, étiquetez tous les fils avant de les

débrancher. Des erreurs de câblage peuvent

entraîner un fonctionnement inadéquat et

dangereux.

Control Adjustments—Digital

The pool heater (chauffe-piscine) touchpad, located

on the upper front panel of the heater, allows the user

to select either POOL or SPA operation, and to adjust

the setpoint temperature. The LCD display window

indicates the mode (OFF, SPA, POOL) and the actual

water temperature. A manual power switch provided

below the touchpad turns the control power ON or

OFF.

OWNER’S OPERATING

INSTRUCTIONS

Control Adjustments—Analog

The pool or spa water temperature is controlled by the

thermostat on the upper front panel of the heater. The

control center contains an On/Off toggle switch and a

thermostat. The switch functions as a means for turn-

ing the heater On or Off.

The thermostat is fitted with a means of limiting the

upper temperature limit below the maximum level. The

knob stop adjustment ring shown in Fig. 17 is

adjustable by loosening the set screw, rotating the

knobstop ring to the desired location, and retightening

the set screw.

HOT

COOL

Knobstop Ring

Knobstop Set Screw

Fig. 17: Water Temperature Thermostat

NOTE: Maximum temperature is 104°F (40°C).

Fig. 18: Digital Control Adjustment

MENU/SET Button

The MENU/SET button is used to select either POOL

or SPA operation. It also allows the user to turn the

heater off electronically. The LCD remains energized

and displays OFF, while also continuing to show the

actual water temperature.

Temp Buttons

If the heater is in POOL or SPA mode, the desired

water temperature (SETPOINT) will also be displayed

and may be adjusted using the UP or DOWN buttons.

Operation

In the POOL or SPA modes, the actual water temper-

ature is displayed along with the desired water

temperature (SETPOINT). When the water tempera-

ture is above the setpoint, “Water Temp” will alternate

with “No Demand.” When the water temperature is

below the setpoint and the heater is firing, “Water

Temp” will alternate with “Heating.”

To adjust the setpoint temperature, make sure the con-

trol is in the appropriate mode (POOL or SPA) and

push the UP or DOWN buttons.

ALTERNATING DISPLAYS DURING HEATING

Service Menu and Fault History

To access the Service Menu and fault history, press

the MENU/SET and UP buttons simultaneously for 3 to

5 seconds. The heater will continue to operate nor-

mally while in the Service Menu. The first screen

displayed is the Flame Strength indicator, which indi-

cates the pilot flame current using a bar graph and

numerical display. A signal of less than 4 indicates a

weak flame signal and may require service. Refer to

Section 5 – Troubleshooting for possible causes and

corrections.

Program

button

FLAME STRENGTH INDICATOR

SUPPLY VOLTAGE INDICATOR

RUN TIME INDICATOR

Press the DOWN button. The Supply Voltage screen

indicates the voltage supplied to the control board.

Normal readings range from 24 to 29 volts.

Press the DOWN button. The Run Time indicates the

total hours of operation for the pool heater, as meas-

ured by the amount of time that the main gas valve has

been powered. The Cycle count indicates the number

of on/off cycles of the heater, as measured by the

number of times the pilot valve has been powered.

FAULT HISTORY

Press the DOWN button. The Fault History can dis-

play up to ten faults in memory. The order of the faults

begins with “Fault Last,” which is the most recent fault,

and proceeds through ten most recent messages in

chronological order. The second line of the display

shows the fault message. If there are no faults in the

history buffer, the second line reads “All Faults Clear.”

Thermostat Operation—

Advanced Flame Technology (AFT) Board

Resets board to factory default

settings.

Resets faults in the History File.

Change from Fahrenheit to

Celsius.

SPA setpoint maximum adjustment.

POOL setpoint maximum

adjustment.

Set Factory Defaults

Refer to step one above to access the program

screen. Set Factory Defaults should appear on the

screen. If it does not, press the MENU/SET button until

Set Factory Defaults appears on the digital display.

Press and hold both UP and DOWN buttons for 5-7

seconds until Defaults Set appears. This operation

resets the operating program to its factory default val-

ues. Both the POOL and SPA setpoints will revert to

65°F (18.5°C) and both POOL and SPA maximum

temperature settings will be 104°F (40.0°C). The

Control Lockout PIN will be cleared and the control will

resume normal operation.

Clear Faults

Refer to step one above to access the program

screen. Press the MENU/SET button until Clear

Faults appears on the digital display. Press and hold

both UP and DOWN buttons for 5-7 seconds until

Faults Cleared appears. This operation resets the

Fault History file to “0” and clears all the stored faults.

Program Button

1) Remove the four screws holding the control cover,

and swing the panel down so the back side of the

board is visible (see page 31). Locate the Program

Mode button (marked as SW1) as shown on page

33. Press and hold the button (5-7 seconds) until

Set Factory Defaults appears on the display.

Release the program button.

2) Press the MENU/SET button sequentially until the

desired program event is reached. There are 5 dif-

ferent events that can be programmed. They

appear in the sequence listed below:

Fahrenheit or Celsius

Refer to step one above to access the program

screen. Press the MENU/SET button until Fahrenheit

or Celsius appears on the digital display. The digital

display is capable of displaying Celsius as well as

Fahrenheit temperatures. The UP or DOWN buttons

will select Fahrenheit or Celsius on the temperature

display. Choose the desired temperature scale.

Spa Max Temp – Spa Set Point Maximum

Adjustment

Refer to step one above to access the program

screen. Press the MENU/SET button until Spa Max

Temp appears on the digital display. Using the UP and

DOWN buttons will change the Maximum Temperature

Setting to your desired value. The control can be set

for a maximum of 107°F (41.7°C).

Pool Max Temp – Pool Set Point Maximum

Adjustment

Refer to step one above access into the program

screen. Press the MENU/SET button until Pool Max

Temp appears on the digital display. Using the UP and

DOWN buttons will change the Maximum Temperature

Setting to your desired value. The control can be set

for a maximum of 107°F (41.7°C).

Control Lockout

The heater is equipped with a Control Lockout feature

to prevent unauthorized tampering or adjustment of

the control settings. To lock out the controls, press the

DOWN button and MENU/SET button for 5 seconds.

Choose a three digit PIN, using the UP and DOWN

buttons to select the digits and the MENU/SET button

to lock in selections. Confirm your selection and

record your PIN.

To unlock the controls, press any button to bring up the

Enter PIN menu. Enter the PIN that was used to lock

the control. Note that power cycling will not clear the

lockout. Successfully unlocking the control will display

“Lockout Cleared.” Failure to enter the correct PIN will

display “Invalid PIN.”

In the event that the user-selected PIN is lost or does

not clear the Control Lockout, use the Program Button

to Set Factory Defaults. This will clear the PIN and

allow normal operation and selection of a new PIN if

desired. See the Program Button directions on this

page for details.

NOTE: Both the POOL and SPA setpoints will revert

back to 65°F (18.5°C) and the POOL and SPA maxi-

mum temperature settings will be 104°F (40.0°C).

These setpoints will need to be readjusted to desired

settings.

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Raypak 106 Installation & Operating Instructions Manual

Brand: Raypak

Model: 106

Category: Above ground pool accessories

Type: Installation & Operating Instructions Manual

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